Robotic arm with a detachable and mobile end-effector

ABSTRACT

The present disclosure is directed toward a robotic system that includes a robotic arm, a robotic end-effector, a lock, and a control system. The robotic end-effector is detachably coupled to the robotic arm and includes a locomotion device to move the robotic end-effector independent of the robotic arm. The lock is disposed with the robotic arm and robotic end-effector, and is operable to detach and attach the robotic arm and the robotic end-effector. The control system is configured to control the robotic arm and the robotic end-effector, and to operate the lock to detach and attach the robotic arm and the robotic end-effector.

FIELD

The present disclosure relates to robotic system, and more particularlyto a robotic arm having an end-effector.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

In recent years, advancements in robotic systems have includeddevelopment of robotic arms used for maneuvering and modifying anobject, such as vehicle panels, doors, console, floor-pan, etc. Therobotic arm typically includes an end-effector that interacts with theobject and can have different configurations based on the application ofthe robotic system. The range of motion of the end-effector is dependenton the robotic arm, and thus, the capabilities and functionality of theend-effector can be limited to the operational limitations of therobotic arm. These and other issues are addressed by the teachings ofthe present disclosure.

SUMMARY

This section provides a general summary of the disclosure and is not acomprehensive disclosure of its full scope or all of its features.

In one form, the present disclosure is directed toward a robotic systemthat includes a robotic arm, a robotic end-effector, a lock, and acontrol system. The robotic end-effector is detachably coupled to therobotic arm, and includes a locomotion device to move the roboticend-effector independent of the robotic arm. The lock is disposed withthe robotic arm and robotic end-effector, and is operable to detach andattach the robotic arm and the robotic end-effector. The control systemis configured to control the robotic arm and the robotic end-effector,and operates the lock to detach and attach the robotic arm and therobotic end-effector.

In another form, the locomotion device includes one or more wheels, oneor more legs, a propeller system, or a combination thereof.

In yet another form, the robotic arm defines an inner channel, and therobotic end-effector is communicably coupled to the control system byway of a cable extending through the inner channel. In one variation,the robotic system further includes a fluid tube disposed within theinner channel to fluidly couple a fluid supply and the roboticend-effector. The robotic end-effector includes a nozzle for dispensingfluid provided via the fluid tube.

In one form, the control system and the robotic end-effector arecommunicably coupled via a wired communication link, a wirelesscommunication link, or a combination thereof.

In another form, the robotic end-effector includes a power terminal, arechargeable battery, a power distribution circuit, or a combinationthereof.

In yet another form, the robotic arm is a hyper redundant manipulator.

In one form, the lock is one of an electromagnetic lock, an electricstrike lock, or an electronic latch lock.

In another form, the robotic end-effector includes a controllercommunicably coupled to the control system. The controller controls therobotic end-effector based on a command from the control system.

In yet another form, the robotic end-effector includes a positiondetector to monitor a position of the robotic end-effector, and thecontrol system locates the robotic end-effector based on data from theposition detector. In one variation, the position detector includes acamera, ultrasonic sensor, a laser, a light detection and rangingdevice, or a combination thereof. In yet another variation, the controlsystem performs one or more visual processes based on the data from theposition detector. The visual processes include inspecting an object,detecting an obstacle, identifying one or more objects about the roboticend-effector, or a combination thereof.

In one form, the robotic end-effector includes a reservoir to hold afluid and a nozzle to dispense the fluid.

In one form, the present disclosure is directed towards a robotic systemthat includes a robotic arm, a robotic end-effector, one or moreposition sensors, an electronic lock, and a control system. The roboticend-effector is detachably coupled to a distal end of the robotic arm,and includes a locomotion device to move independent of the robotic arm.The position sensors monitor the position of the robotic arm, and therobotic end-effector. The electronic lock is disposed with the roboticarm and the robotic end-effector, and is operable to detach and attachthe robotic arm and the robotic end-effector. The control system isconfigured to control the robotic arm and the robotic end-effector basedon data from the position sensors, and operates the lock to detach andattach the robotic arm and the robotic end-effector.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIGS. 1A, 1B, and 1C illustrate a robotic system in accordance with theteaching of the present disclosure;

FIG. 2 illustrates a block diagram of a robotic end-effector inaccordance with the teaching of the present disclosure;

FIGS. 3A and 3B illustrate a first form of a robotic end-effector inaccordance with the teaching of the present disclosure; and

FIG. 4 illustrates a second form of a robotic end-effector in accordancewith the teaching of the present disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

Referring to FIGS. 1A to 1C, a robotic system 100 of the presentdisclosure includes a robotic arm 102 extending from a base 103, arobotic end-effector 104, a lock 106, one or more position sensors 107 ₁to 107 ₃ (collectively sensors 107), and a control system 108 to controlthe robotic arm 102 and the robotic end-effector 104.

As described herein, the robotic end-effector 104 is detachable from therobotic arm 102, and is operable independent of the robotic arm 102.More particularly, in an example application, the robotic system 100 isoperable to inspect and/or modify an object 110, such as vehicle floor.For example, the robotic system 100 may deposit a material on the object110, such as paint, and then inspect the object 110 for any defects,flaws, etc. The robotic end-effector 104 may be detached from therobotic arm 102 to access areas outside the reach of the robotic arm102. That is, in the detached state, the robotic end-effector 104 ismoveable along the object 110 to locations that may not be reachable bythe robotic arm 102. FIG. 1A illustrates the robotic end-effector 104 inan attached state. FIG. 1B illustrates a wired configuration between arobotic end-effector 104A and the control system 108 in which therobotic end-effector 104A is detached from a robotic arm 102A withcables 111 extending through the arm 102A to the robotic end-effector104A. FIG. 1C illustrates a wireless configuration in which a roboticend-effector 104B is detached from a robotic arm 102B with no wiresextending therebetween. In the example of FIG. 1C, the control system108 and the robotic end-effector 104B are communicably coupled via awireless communication link. Accordingly, in both wired and wirelessconfiguration, the robotic end-effector 104 is moveable and operableindependent of the robotic arm 102. Details regarding the end-effector104 is described further herein. While the object is illustrated as avehicle floor, the object may a dashboard provided within a vehicle, orother suitable component not limited to a vehicle.

In one form, the robotic arm 102 is a snake-arm robot (e.g., a hyperredundant manipulator) having multiple degrees of freedom to allow therobotic arm 102 to move along a straight path or even in a wave form,like a snake. The robotic arm 102 may be another suitable robot such asan articulated robot, cartesian robot arm, cylindrical robot arm, and/orspherical robot arm. In one form, the robotic arm 102 defines an innerchannel 112 for housing cables/wires connected between the controlsystem 108 and the end-effector 104. Alternatively, the cables may berouted along the outside of the robotic arm 102. In one form, therobotic arm 102 is configured to retract/extend the cables based on themovement of the end-effector 104.

In one form, the lock 106 includes an arm interface 106A disposed at therobotic arm 102 and an end-effector interface 106B disposed with theend-effector 104. In one form, the lock 106 is an electronic lock, suchas an electromagnetic lock, an electric strike lock, an electronic latchlock. The control system 108 is configured to operate the lock 106 bycontrolling electric current to the lock 106 and thus,attaching/detaching the robotic end-effector 104 to/from the robotic arm102. In one form, the lock 106 is integrated with a distal end of therobotic arm 102 and with the end-effector 104.

The position sensors 107 are disposed throughout the robotic system 100to monitor the work environment and detect obstacles, and to monitor thepositions of the robotic arm 102 and the end-effector 104. In one form,the sensors 107 include a camera, an ultrasonic sensor, a laser, a lightdetection and ranging (LIDAR) device, and/or other suitable sensor. Datafrom the position sensors 107 is provided to the control system 108 forfurther processing.

The control system 108 is configured to control the various componentsof the robotic system 100 to perform one or more tasks, such asinspecting and/or modifying the object 110. In one form, the controlsystem 108 includes a combination of electronic hardware (e.g.,microprocessors, non-transitory computer readable memory, transceivers,input/output interface ports, and/or other suitable electronics) andsoftware programs executed able by the microprocessor. The controlsystem 108 may also be communicably coupled to external components, suchas a computing device operable by a technician for controlling therobotic system 100, and/or an external server system that collects datato monitor performance of the robotic system 100. In operation, thecontrol system 108 processes the data from the position sensors 107 tocontrol the movement of the robotic arm 102 and the robotic end-effector104 using one or more software programs stored by the system 108. Forexample, based on data from the position sensors 107, the control system108 may detect an obstacle, and then control the robotic arm 102 and/orthe robotic end-effector 104 to avoid the obstacle.

Based on the application having the robotic system 100, the controlsystem 108 may be configured to control auxiliary devices required toperform one or more tasks related to the application. For example, inone form, the robotic system 100 applies a fluid (e.g., paint, powdermetal, etc.) on a surface of the object 110. More particularly,referring to FIG. 1, the robotic system 100 includes a fluid tube 114disposed within the inner channel 112 that is connected to a fluidsupply (not shown) and to the robotic-end-effector 104. As describedbelow, the robotic end-effector 104 includes a nozzle for dispensingfluid from the fluid tube 114. In this application, the control system108 is configured to control the amount of fluid being dispensed fromthe robotic end-effector 104, and inspect the painted area of the object110 using the position sensor and/or the robotic end-effector 104. Therobotic system 100 may be adapted for different applications, and shouldnot be limited to the examples described herein.

The robotic end-effector 104 of the present disclosure is configured tooperate with and independent from the robotic arm 102. Referring to FIG.2, in one form, the robotic end-effector 104 includes a power source202, a communication interface 204, a locomotion device 206, a positiondetector 208, and a controller 210,

The power source 202 provides power to the various electronic componentsof the robotic end-effector 104. The power source 202 includes, forexample, a rechargeable power supply (e.g., a battery) disposed withinthe end-effector 104, a power distribution circuit connected to powersupply via a power cable, a power terminal, or a combination hereof.

The communication interface 204 communicably couples the roboticend-effector 104 to the control system 108. For example, in one form,the communication interface 204 includes an input/output interface(e.g., a port) to connect to a cable/wire that is connected to thecontrol system 108. In another form, the communication interface 204includes a transceiver to establish wireless communication with thecontrol system 108 via short-range communication link (e.g., BLUETOOTH,ZIGBEE, WI-FI, etc). In yet another form, the communication interface204 is configured for both wired and wireless communication, andtherefore, includes an I/O interface and a transceiver.

The locomotion device 206 moves the robotic end-effector 104 independentof the robotic arm 102. The locomotion device 206 includes, for example,legs, wheels, and/or a propeller system to move the robotic end-effector104 along the surface of the object 110, around the object 110, or acombination thereof.

The position detector 208 monitors the position of the roboticend-effector and the environment about the end-effector 104, and may bean extension of the position sensor 107. The position detector 208 mayinclude one or more sensors disposed about the end-effector 104, such asa camera, ultrasonic sensor, a laser, a light detection and ranging(LIDAR), or a combination thereof. Data from the position detector 208is provided to the controller 210 and/or the control system 108 toperform one or more visual processes, such as aligning the roboticend-effector 104 with the robotic arm 102, determining a location of therobotic end-effector 104, inspecting the object 110, identifying one ormore components/obstacles about the robotic end-effector 104, or acombination thereof.

The controller 210 includes a combination of electronic hardware (e.g.,microprocessors, non-transitory computer readable memory, and/or othersuitable electronics) and software programs executed by themicroprocessor. The controller 210 controls the components of therobotic end-effector 104 and is configured to perform various tasksbased on the application of the robotic system 100. The controller 210is communicably coupled to the control system 108 via the communicationinterface 204 to exchange data with the control system 104. For example,the controller 210 transmits data from the position detector 208 to thecontrol system 108 and receives commands, such as: requesting theend-effector 104 to move to a location along the object 110; having theend-effector 104 inspect an area; dispensing fluid along a selectedsurface of the object 110; positioning the end-effector 104 with therobotic arm 102 to attach to the robotic arm 102 via the lock 106;and/or requesting the controller 210 to execute a program stored by thecontroller 210. While specific example operations of the controller 210is provided, it should be readily understood that the controller 210 canbe configured to perform is various suitable ways based on theapplication of the robotic system 100.

In one form, the end-effector 104 may include auxiliary devices toperform a particular task. For example, in one form, the end effectormay include a fluid dispenser 212 for depositing a fluid on the object110. The auxiliary device may be other suitable device/components, suchas a tool for joining components, or an imaging device for inspectingcomponents, and should not be limited to the fluid dispenser 212.

In one form, FIGS. 3A and 3B illustrate a robotic end-effector 300 inaccordance with the teaching of the present disclosure. The roboticend-effector 300 is configured to communicate with the control system108 via a wired communication link and dispense fluid. Here, the powersource includes a power terminal 302 to connect to a power cable (notshown) and a power distribution circuit 304 to supply power tocomponents of the end-effector 300 from a power supply (not shown)connected to the power cable. The communication interface includes anI/O port 306 to communicably couple a controller 308 with the controlsystem 108 via a cable (not shown). The locomotion device includeswheels 310 ₁ to 310 ₄ to move the end-effector 300, and in one form, areretractable wheels that extend when the end-effector 300 is detached andretract into the body 114 of the end-effector 300 when attached to thearm. The position detector includes multiple sensors 312 disposed alonga body 314 of the end-effector 300 for monitoring the position and theenvironment of the end-effector 300. The sensors 312 may include acamera, ultrasonic sensor, a laser, a light detection and ranging(LIDAR), or a combination thereof. The location of the sensors 312 alongthe body 114 should not be limited to the arrangement illustrated. Thefluid dispenser includes a fluid port 316 to connect to the fluid supplyvia a fluid tube, a fluid channel 318 defined within the end-effector300, and a nozzle 320 connected to an end of the fluid channel 318 toreceive and dispense the fluid.

Referring to FIG. 4, in another form, a robotic end-effector 400 isconfigured to communicate with the control system 108 via a wirelesscommunication link and is configured as a drone to include a propellersystem. Here, the power source includes a rechargeable battery 402 thatis configured to power the components of the end-effector 400 via apower distribution circuit (not shown), and a power terminal 404 thatconnects to a power cable (not shown) when the end-effector 400 isattached to the robotic arm 102 to charge the battery 402. Thecommunication interface includes a transceiver 406 to communicablycouple a controller 408 with the control system 108 via a wirelesscommunication link. The locomotion device includes a propeller system410 that multiple propellers 412 driven by electric motors 414. Thepropeller system is controllable by the controller 408. Like endeffector 300, the position detector includes multiple sensors 416disposed along a body 418 for monitoring the position and theenvironment of the end-effector 400. The fluid dispenser includes afluid port 420, a reservoir 422 to hold fluid, a fluid channel 424defined between the port 420 and the reservoir 422, and a nozzle (notshown) fluidly coupled to the reservoir 422 to dispense the fluid. Whenattached to the robotic arm 102, the fluid port 420 is connected to thefluid tube which supplies fluid to the reservoir 422.

The robotic end-effector of the present disclosure may be configured inother suitable ways and should not be limited to the roboticend-effectors 300 and 400. For example, the robotic end-effector mayinclude legs in lieu of wheel, both a propeller system and legs/wheels,a transceiver and I/O port, and/or no fluid dispenser.

The robotic end-effector of the present disclosure is operableindependent of the robotic arm to reach areas of the object not easilyaccessible by the robotic arm. For example, in one application, in lieuof using wires, the robotic system of the present disclosure isconfigured to print circuits on body panels using conductive anddielectric paints. The robotic end-effector is configured accessopenings unreachable by the arm and is movable along multiple dimensionsto paint the circuit and/or test the electrical characteristics of thecircuit. Accordingly, the robotic system of the present disclosureincreases the workable area of the system.

Unless otherwise expressly indicated herein, all numerical valuesindicating mechanical/thermal properties, compositional percentages,dimensions and/or tolerances, or other characteristics are to beunderstood as modified by the word “about” or “approximately” indescribing the scope of the present disclosure. This modification isdesired for various reasons including industrial practice, manufacturingtechnology, and testing capability.

As used herein, the phrase at least one of A, B, and C should beconstrued to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least oneof B, and at least one of C.”

The description of the disclosure is merely exemplary in nature and,thus, variations that do not depart from the substance of the disclosureare intended to be within the scope of the disclosure. Such variationsare not to be regarded as a departure from the spirit and scope of thedisclosure.

What is claimed is:
 1. A robotic system comprising: a robotic arm; arobotic end-effector detachably coupled to the robotic arm, wherein therobotic end-effector includes a locomotion device to move the roboticend-effector independent of the robotic arm; a lock disposed with therobotic arm and robotic end-effector and operable to detach and attachthe robotic arm and the robotic end-effector; and a control systemconfigured to control the robotic arm and the robotic end-effector,wherein the control system operates the lock to detach and attach therobotic arm and the robotic end-effector.
 2. The robotic system of claim1, wherein the locomotion device includes one or more wheels, one ormore legs, a propeller system, or a combination thereof.
 3. The roboticsystem of claim 1, wherein the robotic arm defines an inner channel, andthe robotic end-effector is communicably coupled to the control systemby way of a cable extending the through the inner channel.
 4. Therobotic system of claim 3 further comprising a fluid tube disposedwithin the inner channel to fluidly couple a fluid supply and therobotic end-effector, wherein the robotic end-effector includes a nozzlefor dispensing fluid provided via the fluid tube.
 5. The robotic systemof claim 1, wherein the control system and the robotic end-effector arecommunicably coupled via a wired communication link, a wirelesscommunication link, or a combination thereof.
 6. The robotic system ofclaim 1, wherein the robotic end-effector includes a power terminal, arechargeable battery, a power distribution circuit, or a combinationthereof.
 7. The robotic system of claim 1, wherein the robotic arm is ahyper redundant manipulator.
 8. The robotic system of claim 1, whereinthe lock is one of an electromagnetic lock, an electric strike lock, oran electronic latch lock.
 9. The robotic system of claim 1, wherein therobotic end-effector includes a controller communicably coupled to thecontrol system, the controller controls the robotic end-effector basedon command from the control system.
 10. The robotic system of claim 1,wherein: the robotic end-effector includes a position detector tomonitor a position of the robotic end-effector, and the control systemlocates the robotic end-effector based on data from the positiondetector.
 11. The robotic system of claim 10, wherein the positiondetector includes a camera, ultrasonic sensor, a laser, a lightdetection and ranging device, or a combination thereof.
 12. The roboticsystem of claim 10, wherein the control system performs one or morevisual processes based on the data from the position detector, thevisual processes includes inspecting an object, detecting an obstacle,identifying one or more objects about the robotic end-effector, or acombination thereof.
 13. The robotic system of claim 1, wherein therobotic end-effector includes a reservoir to hold a fluid and a nozzleto dispense the fluid.
 14. A robotic system comprising: a robotic arm; arobotic end-effector detachably coupled to a distal end of the roboticarm, wherein the robotic end-effector includes a locomotion device tomove independent of the robotic arm and a position detector to monitorposition of the robotic end-effector; one or more position sensorsmonitoring the position of the robotic arm and the robotic end-effector;an electronic lock disposed with the robotic arm and the roboticend-effector and operable to detach and attach the robotic arm and therobotic end-effector; and a control system configured to control therobotic arm and the robotic end-effector based on data from the positionsensors, wherein the control system operates the lock to detach andattach the robotic arm and the robotic end-effector.
 15. The roboticsystem of claim 14, wherein the locomotion device includes one or morewheels, one or more legs, a propeller system, or a combination thereof.16. The robotic system of claim 14, wherein the robotic arm defines aninner channel, and the robotic end-effector is communicably coupled tothe control system by way of a cable extending through the innerchannel.
 17. The robotic system of claim 14, wherein the control systemand the robotic end-effector are communicably coupled via a wiredcommunication link, a wireless communication link, or a combinationthereof.
 18. The robotic system of claim 14, wherein the positiondetector includes a camera, ultrasonic sensor, a laser, a lightdetection and ranging device, or a combination thereof.
 19. The roboticsystem of claim 14, wherein the robotic arm is a hyper redundantmanipulator.
 20. The robotic system of claim 14, wherein the electroniclock is one of an electromagnetic lock, an electric strike lock, or anelectronic latch lock.